WO2013177670A1 - Industrial textiles comprised of bi-axially oriented, hydrolytically stabilized polymer film - Google Patents

Industrial textiles comprised of bi-axially oriented, hydrolytically stabilized polymer film Download PDF

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Publication number
WO2013177670A1
WO2013177670A1 PCT/CA2013/000515 CA2013000515W WO2013177670A1 WO 2013177670 A1 WO2013177670 A1 WO 2013177670A1 CA 2013000515 W CA2013000515 W CA 2013000515W WO 2013177670 A1 WO2013177670 A1 WO 2013177670A1
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Prior art keywords
film
layer
industrial textile
layer comprises
film thickness
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PCT/CA2013/000515
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French (fr)
Inventor
Allan R. MANNINEN
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Astenjohnson, Inc.
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Publication of WO2013177670A1 publication Critical patent/WO2013177670A1/en

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/36Layered products comprising a layer of synthetic resin comprising polyesters
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001Combinations of extrusion moulding with other shaping operations
    • B29C48/0018Combinations of extrusion moulding with other shaping operations combined with shaping by orienting, stretching or shrinking, e.g. film blowing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07Flat, e.g. panels
    • B29C48/08Flat, e.g. panels flexible, e.g. films
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/10Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/06Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00Layered products comprising a layer of synthetic resin
    • B32B27/18Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/033 layers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00Layers arrangement
    • B32B2250/24All layers being polymeric
    • B32B2250/244All polymers belonging to those covered by group B32B27/36
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10Inorganic particles
    • B32B2264/102Oxide or hydroxide
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/40Properties of the layers or laminate having particular optical properties
    • B32B2307/402Coloured
    • B32B2307/4026Coloured within the layer by addition of a colorant, e.g. pigments, dyes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/514Oriented
    • B32B2307/518Oriented bi-axially
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/50Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54Yield strength; Tensile strength

Definitions

  • the invention generally concerns hydrolytically stabilized, bi-axially oriented polymeric films. It is particularly concerned with the use of such films in the manufacture and production of components for industrial textiles and other applications where durability and stability in adverse environmental conditions are important.
  • Appropriate polymeric materials for the film include, but are not limited to, hydrolysis stabilized polyethylene terephthalate (PET), polybutylene terephthalate (PBT),
  • the present invention is directed at films suitable for industrial textiles, and such industrial textiles and components thereof such as are described by Manninen in WO 2011/069259, WO 2010/121360, WO 2011/069258, and CA 2,749,477 and which are comprised of bi-axially oriented hydrolytically stabilized polymer films which are resistant to heat, humidity and abrasive wear. It is particularly concerned with such textiles which are intended for use in continuous process applications. These include, but are not limited to, papermaking, where they may be employed as dryer fabrics, through- air dryer (TAD) fabrics, transfer fabrics, press felts, forming fabrics and the like; stock preparation processes such as pulp thickening, pulp forming or in chemi-washers;
  • TAD through- air dryer
  • agrochemicals preparation such as separation of phosphoric acid in the preparation of potash; solar panels; formation of various construction and building materials such as medium density fiberboard (MDF) and shingles; food drying and related dehydration processes; and formation of nonwoven products in continuous dry laid, wet laid and polymer laid processes.
  • MDF medium density fiberboard
  • textiles intended for use in such industrial processes must be rugged, so as to be capable of surviving the various environmental conditions to which they are exposed during their service life, including the following: abrasion caused by their continuous movement over various stationary elements in the machines in which they are used; high heat and prolonged humidity normally encountered in various drying processes which leads to hydrolytic degradation of the constituent polymers that make up at least a portion of the textile components; and chemical degradation caused by prolonged exposure to acids and bases in various processes.
  • the textile components from which these fabrics are made must be very durable and as resistant as possible to the various environmental conditions to which they are exposed.
  • Bi-axially oriented hydrolytically stabilized polyester films are known.
  • US 6,855,758 to Murschall et al. discloses a hydrolysis resistant bi-axially oriented transparent film made from a crystallizable thermoplastic polyester including a hydrolysis stabilizer consisting of a bond restoration agent such as a monomeric or polymeric carbodiimide and optionally at least one of either a phenolic compound or organic phosphate.
  • the film is said to exhibit good optical properties, in that it has a high light transmittance (above 80%), low haze and a low Yellowness Index (YI), i.e. below 10.
  • YI Yellowness Index
  • carbodiimide type hydrolysis stabilizers such as Stabaxol® P are milky in appearance and, for this reason, films which include a carbodiimide hydrolysis stabilizer cannot generally have overall thicknesses greater than ⁇ without becoming at least partially opaque, which would not provide the required optical properties of the film.
  • the films produced in accordance with the teachings of Murschall et al. must necessarily have a thickness of less than ⁇ , so as to be at least partially transparent. Films of this thickness or less would be unsuitable for use in industrial textiles intended for use in industrial processes such as papermaking and filtration such as are described above, and are not contemplated in the reference. US 6,020,056 to Walker et al.
  • the PET has an initial IV of from 0.95 to 1.1 and, when cast, has an IV of from about 0.8 to 1.0; the resulting film is stretched and oriented at least two times in the machine and cross- machine directions to provide a final monolayer film having an intended end use as a motor insulation.
  • WO 2011/030098 to Brennan et al. discloses a bi-axially oriented PET film further including a hydrolysis stabilizer which is a glycidyl ester of a branched monocarboxylic acid having from 5 to 50 carbon atoms and which is present in the film as its reaction product along with some of the polyester end-groups.
  • a hydrolysis stabilizer which is a glycidyl ester of a branched monocarboxylic acid having from 5 to 50 carbon atoms and which is present in the film as its reaction product along with some of the polyester end-groups.
  • the proposed benefit of this stabilizer is the alleged lack of toxic by-products and economy of manufacture.
  • Use of the film as a layer in a photovoltaic cell is disclosed.
  • polyesters can include any aliphatic or aromatic filament forming polyester (e.g. PET) with preference given to those having a molecular weight corresponding to an intrinsic viscosity (IV) of at least 0.64 and preferably at least 0.7 dL/g as measured in dichloroacetic acid at 25°C.
  • IV intrinsic viscosity
  • a film for use in an industrial textile, or textiles and components thereof comprising a bi-axially oriented, multi-layer hydrolytically stabilized polymeric film.
  • the film is not required to be transparent, and for some applications opacity may be advantageous, for example for purposes of monitoring the condition of the film, or a product being conveyed by the film.
  • the film may include, for example, a suitably profiled and apertured film, or an industrial textile constructed of the film, or a component of such textile, such as a nonwoven seaming element, such as are described in the aforementioned patent applications in the name of the present inventor.
  • a suitable film should be formed from a medium to high IV polyester; the IV should be between about 0.55 and 1.0. At least one layer of the film must also be hydrolytically stabilized to prevent premature depolymerization in hot and moist environments due to hydrolytic degradation; carbodiimides are preferred for this application.
  • the film must be stretched and oriented as it is produced so as to increase and maximize its elastic modulus and other physical properties, in particular its tensile strength, which should be at least about 140 Mpa in the machine direction (MD) and 165 MPa in the transverse direction (TD) (also known as cross-machine direction, (CD)) in the finished film, and its free shrinkage, which should be in the range of from 0.5% to no more than 2% in each of the MD and TD, and is preferably about 1 % in each.
  • MD machine direction
  • TD transverse direction
  • CD cross-machine direction
  • the film is comprised of at least two and preferably three coextruded miscible layers in which at least one outer layer comprises from 5% to 20% of the overall film thickness which may be from about 100 up to 500 ⁇ , but in most cases preferably in the range of about 250 to 350 ⁇ . This caliper should be uniform throughout.
  • the present invention seeks to provide an industrial textile comprising a biaxially oriented multilayer thermoplastic film including at least two coextruded film layers, wherein
  • each layer comprises a polyester having an intrinsic viscosity (IV) of at least
  • At least a first layer comprises a hydrolytic stabilizer comprising a carbodiimide
  • the film has a thickness of at least 1 ⁇ and
  • the first layer of the film comprises at least 5% of the film thickness.
  • the invention further seeks to provide a biaxially oriented multilayer thermoplastic film, wherein
  • each layer comprises a polyester having an intrinsic viscosity (IV) of at least 0.5;
  • At least one layer comprises a hydrolytic stabilizer comprising a carbodiimide
  • the film has a thickness of at least ⁇ .
  • the polyester for each layer of the film or textile is selected from one of PET, PBT, PEN, PCTA, and more preferably the polyester for each layer is PET.
  • the IV is in the range of 0.5 to 1.0.
  • the film thickness is in the range of ⁇ to 500 ⁇ .
  • a first layer comprises from 5% to 15% of the film thickness and the second layer comprises from 85% to 95% of the film thickness; and more preferably the first layer comprises substantially 10% of the film thickness and the second layer comprises substantially 90% of the film thickness.
  • the film or industrial textile comprises three layers, preferably each outer layer comprises from 5% to 20% of the film thickness and an inner layer comprises from 60% to 90% of the film thickness; and more preferably each outer layer comprises from 10% to 15%) of the film thickness and the inner layer comprises from 70% to 80% of the film thickness.
  • the carbodiimide comprises between 0.5%pbw and 5%pbw of the material of that layer.
  • the carbodiimide is selected from a monomelic form and a polymeric form, more preferably the carbodiimide is polymeric.
  • the film is stretched in each of a longitudinal and a transverse direction by a factor of from two to at least four, more preferably by a factor of at least three.
  • the resulting film is subsequently annealed, cooled and formed into rolls for later use.
  • At least one layer further comprises an additive, such as at least one of carbon black, titanium dioxide, and at least one dye.
  • an additive such as at least one of carbon black, titanium dioxide, and at least one dye.
  • At least one layer further comprises an antiblock agent.
  • At least one layer further comprises a radiant energy absorbent material.
  • the invention further seeks to provide an industrial textile comprising a biaxially oriented multilayer thermoplastic film according to the films of the invention.
  • the invention still further seeks to provide a component for use with an industrial textile, comprising a film strip prepared from a film according to the invention.
  • the invention still further seeks to provide a component for use in an industrial textile, the component comprising a biaxially oriented multilayer thermoplastic film including at least two coextruded film layers, wherein
  • each layer comprises a polyester having an intrinsic viscosity (IV) of at least 0.5;
  • At least a first layer comprises a hydrolytic stabilizer comprising a carbodiimide
  • the film has a thickness of at least ⁇ and
  • the first layer of the film comprises at least 5% of the film thickness.
  • the component is constructed of a multilayer thermoplastic film according to the invention.
  • the component comprises a seaming element constructed and arranged to be secured to a seamable edge of the industrial textile.
  • the film has a tensile strength of at least about 140 MPa in each of the MD and the TD. More preferably, the MD tensile strength is at least about 140 MPa and the TD tensile strength is at least about 165 MPa.
  • Tensile strength is measured according to the method provided in ASTM D882 entitled "Standard Test Method for Tensile Properties of Thin Plastic Sheeting" and is a measure of the ultimate or maximum stress of a film at failure.
  • the film has an elongation at break that is at least about 160% in each of the MD and TD as determined according to the method provided in ASTM D882. Elongation at break is the percentage increase in length of the film at failure.
  • the film exhibits a low free shrinkage that is in the range of from about 0.25% to no more than 2% when measured at 150°C for 10 minutes as determined by ASTM D1204 "'Standard Test Method for Linear Dimensional Changes of Nonrigid
  • the free shrinkage is no more than about 1 % when measured according to that method. Free shrinkage is the percentage reduction in a length of film material under zero tension when subjected to a specified temperature.
  • the hydrolysis stabilizer is a carbodiimide and is added to and blended with the polyester in masterbatch form sufficient to comprise from about 0.1% to 5% pbw (parts by weight), preferably about 0.5% to 3% pbw and more preferably about 1.5% to 3% pbw based on the weight of the material in each film layer. Preference is presently given to aromatic polymeric carbodiimides; alternatively the carbodiimide is monomeric.
  • the carbodiimide is incorporated as a masterbatch in the polymer melt.
  • the film When intended for use to form nonwoven industrial textiles or components thereof, the film can be processed in one of several ways. For example, for a slit and profiled textile, it may be cut first to a desired size and then a desired topography imparted by means of a thermoforming process whereby heat and pressure are used to deform the film out of plane into a desired shape. The film can then be slit by either mechanical means or by means of radiant energy such as from tuned laser. Alternatively, the film can first be slit or perforated by chosen means, and then embossed with a suitable pattern. In either case, the slit and profiled film sections are then assembled into nonwoven industrial textiles and associated components using known means. As a further alternative, the film may first be embossed according to a desired pattern, and then assembled in two or more layers, and finally perforated as desired.
  • the films, industrial textiles and components of the invention are formed from an extruded and bi-axially oriented film which is comprised of at least one, and preferably three coextruded polymeric layers that are oriented and heatset together, and which include a hydrolysis stabilizer in the form of a monomeric or polymeric carbodiimide.
  • a hydrolysis stabilizer in the form of a monomeric or polymeric carbodiimide.
  • Hydrolysis is a chemical process by which a water molecule is added to a substance resulting in that substance splitting into two parts. It is the type of reaction that will break down certain polymers, especially those such as PET which are made by condensation polymerization. Hydrolysis stabilizers are often added to PET resins when the intended end product will be used in hot and moist environments.
  • Hydrolysis stabilization additives are well known and function by reacting with free polymeric carboxyl end groups in the polymer melt prior to extrusion.
  • One such additive which has proven successful when incorporated into polyester monofilaments, is
  • Stabaxol® KE7646 This additive is commercially available from Rhein Chemie Corp. of Chardon, OH and is comprised of from about 10% to 30% pbw of a polymeric carbodiimide in 70 to 90% pbw of a high IV PET (IV approx. 0.80).
  • a monomelic form of the Stabaxol® additive is also available and is anticipated to be equally as successful in imparting hydrolysis resistance as the polymeric form; either form is suitable for use in the polymeric films and industrial textiles and components of the invention.
  • higher IV PET resins will allow for the production of a film with improved physical properties, in particular resistance to abrasion and hydrolysis, when compared to films produced from resins of lower IV.
  • High intrinsic viscosity polymer resins will allow the resulting films to better withstand the rigorous demands of certain of the industrial environments to which it may be exposed, such as in the hot and moist dryer section of a papermaking machine, or continuous exposure to sunlight on a solar panel.
  • the Stabaxol® KE7646 is the masterbatch form of a polycarbodiimide; according to the manufacturer, it contains 15% Stabaxol® PI 00 (the active ingredient) uniformly blended in the PET. Addition of 10-20 pbw Stabaxol® KE7646 per 100 pbw PET should provide an active ingredient content of Stabaxol® P100 of 1.5% to 3%, which is the preferred range of carbodiimide hydrolysis stabilizer in the films and components of the present invention. It has been found that compositions including relatively high IV PET (e.g.
  • the films of the invention are made as follows. A desired PET or other polyester resin is first obtained and an appropriate amount of hydrolysis stabilizer is added according to normal blending processes as are known in the art. As previously mentioned, if the end use of the film is as a belt component in a hot and/or humid environment, the polymer should be hydrolysis stabilized and the IV selected as appropriate. The polymer is preferably obtained as resin pellets which are then loaded into the hoppers of the film extruder(s).
  • the polymer melt is then extruded through a slot die according to techniques and equipment common in the industry.
  • the amorphous prefilm is subsequently quenched on a chill roll and then reheated and oriented in both the MD (machine direction) and TD (transverse direction) so as to impart stretch-induced structure through biaxial orientation.
  • This step is important in order to provide a mechanically stable film as the stretching process will straighten out the polymer chains in the film and provide crystals with the desired morphology.
  • Stretching temperatures are normally above the glass transition temperature T g by at least 10°C.
  • the stretching ratio in each of the MD and TD will be about 3, but may range from 2 to about 4 as required.
  • the films of the invention can be made using the simultaneous stretch process, or sequential stretching. Depending on the end use of the film, it may be desired to preferentially stretch the film in one of these directions over the other. A second subsequent stretch in either or both the MD and TD may be employed as needed.
  • the MD and TD shrinkage can be adjusted as appropriate by temperature settings and frame geometry. It should be noted that, as film thickness and carbodiimide content increases, it becomes increasingly difficult to reliably and uniformly control properties, particularly thickness.
  • Heat setting or annealing of the film at oven temperatures of about 180°C to 260°C follows stretch and orientation; the film is then cooled and wound.
  • the oriented film preferably has a final thickness of from about 175 ⁇ to 350 ⁇ ; depending on the intended end use, the film thickness may be increased or decreased around these limits as necessary.
  • Films made according to the process described above should ideally have a tensile strength of at least about 140 MPa in both the MD and the TD so as to be useful in the manufacture of industrial textiles and components thereof.
  • the TD tensile strength of the film will be higher than the MD tensile strength and will be at least about 165 MPa.
  • tensile strength is determined according to the method described in ASTM D882.
  • films made according to the procedure should provide an elongation at break that is at least about 160% in each of the MD and TD, also as determined according to the method provided in ASTM D882.
  • the films of the present invention exhibit a low free shrinkage, i.e.
  • the polyester films of the invention may be monolayer films, but are preferably multilayer and more preferably are comprised of three layers. In experimental trials, the film was extruded using a three layer die with a feedblock designed to feed both outside skins from one extruder and the core layer from another. The resultant film thus included three polymer layers arranged according to an A-B-A configuration in which each of A and B are essentially the same polymer but are of two differing thicknesses.
  • multilayer films of the invention in which the layers A each accounted for 15% of the overall film thickness and the layer B provided the remaining 70% were particularly suitable for use as components in industrial textiles, however, other film thickness ratios such as 10-80-10 may also prove suitable.
  • concentration of the stabilizer may vary from one layer to the next. However, in such structures, it is important that the adjacent layers be compatible, or miscible; alternatively a so-called “tie layer” may be located in between the adjacent layers to prevent layer separation and provide a unified film structure.
  • the hydrolytically stabilized film of the present invention bears some similarities to the coextruded laser weld enabled film described in CA 2,758,622 (Manninen). As described in that document, one layer of the film is different from the others in that it includes a laser weld enabling material. In the present invention, the film is comprised entirely of essentially the same polymer (although a dye or other common additive may be included in one or more of the layers). For example, it may be necessary to provide an antiblock agent, such as Invista V388 (available from Invista S.a.r.l. of Wichita, Kansas) at a 5% pbw concentration, to the outer "A" layers of the film to prevent them from sticking to a roll or other component of the extruder and/or stretching arrangement.
  • an antiblock agent such as Invista V388 (available from Invista S.a.r.l. of Wichita, Kansas) at a 5% pbw concentration
  • the polymer films of the present invention are of particular importance to the industrial textile industry for several reasons. First, they are formed from a higher IV PET resin than others that have been used previously and which are commercially available PET films. It has been found that the high IV PET retards brittle crystal formation during heatsetting/thermoforming steps. Commercially available PET films are formed from polyester resins whose IV is less than 0.5; if exposed to heat in the range of about 200°C or more, or prolonged exposure to sunlight, such films will become very brittle and fail in various ways (their tensile strength will diminish, they will become prone to stress cracking, etc.) whereas the films of the present invention will not degrade in this manner.
  • the grade of the PET resin is important when the end use application involves hydrolysis; generally the resin should have a relatively low carboxyl end group concentration and contain low residual diethylene glycol.
  • the hydrolysis stabilizer is reactive and affects the extensional viscosity of melt of the blend - therefore the stabilizer loading affects the processability of the film. It has been found that the quality of the film is significantly affected by the line process parameters, i.e.
  • films and textile components of the present invention are highly resistant to hydrolytic degradation.
  • samples of film made in accordance with the teachings of the invention retained at least 75% tensile strength after six days.
  • the finished films of the invention can thus be used for the various purposes noted above, where resistance to degradation and embrittlement are important, particularly for the manufacture of industrial textiles which are uniquely suitable for conveyance, filtration and separation processes.
  • hydrolytically stabilized PET film having a thickness of from about 250 ⁇ to about 350 ⁇ is suitable for use in the production of selectively slit and embossed films intended for subsequent assembly as nonwoven papermaking fabrics.
  • Similar films of greater or lesser thickness will be appropriate for the manufacture of seaming components which will be used to join the opposing ends of these fabrics on the machines for which they are intended.

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Abstract

A biaxially oriented multilayer thermoplastic film, and industrial textiles and textile components comprised of the film. Each layer comprises a polyester having an intrinsic viscosity (IV) of at least 0.5; and a hydrolytic stabilizer comprising a carbodiimide, and the film has a thickness of at least 100µm. The carbodiimide provides resistance to depolymerization resulting from prolonged exposure to heat and humidity. The film is preferably produced as a multilayer co-extrusion which is subsequently oriented in each of the machine and transverse directions to maximize its mechanical properties. The final film is processed to render it suitable for use as in nonwoven industrial textiles and textile components with improved durability and longevity.

Description

INDUSTRIAL TEXTILES COMPRISED OF BI-AXIALLY ORIENTED, HYDROLYTICALLY STABILIZED POLYMER FILM
FIELD OF THE INVENTION
The invention generally concerns hydrolytically stabilized, bi-axially oriented polymeric films. It is particularly concerned with the use of such films in the manufacture and production of components for industrial textiles and other applications where durability and stability in adverse environmental conditions are important.
BACKGROUND OF THE INVENTION
Industrial textiles used in filtration, conveyance and similar processes have been and are typically manufactured by weaving, whereby synthetic yarns are interwoven to provide either the entire fabric, or only a base portion which may subsequently be either encapsulated (e.g. with polyurethane or other similar rugged material) or needled to attach a nonwoven batt material. Such fabrics have been satisfactory for these uses, but the cost of their production is high, particularly when the fabrics must be finely and precisely woven using relatively small yarns. Further, these fabrics must be rendered endless in some manner, either by installing a seaming element at their opposed longitudinal ends, or by re-weaving the longitudinal yarns back into the fabric structure to form seaming loops or similar joining means, for secure connection by a pintle, coil or similar securing means. It is also known to weave such fabrics in an endless manner, so that there is no seam, or to interweave the yarns from one longitudinal end into the yarns of the opposed end to form a woven seam. These fabrics are expensive to produce and require a high capital investment in wide industrial looms and similar related equipment for subsequent processing, as well as a skilled workforce to operate the equipment and produce an acceptable finished product.
It has recently been proposed by Manninen (WO 201 1/069259) to construct nonwoven fabrics suitable for the same or similar processes as those which currently use woven fabrics by using selectively slit and embossed polymeric films. It is also proposed to form components from suitably shaped and processed film for use in seaming both these nonwoven and woven textiles (see WO 2010/121360, WO 2011/069258, or CA 2749477). The '259 document proposes that thermoplastic polymeric films used in such fabrics should be bi-axially oriented and rendered hydrolysis resistant by known means.
Appropriate polymeric materials for the film include, but are not limited to, hydrolysis stabilized polyethylene terephthalate (PET), polybutylene terephthalate (PBT),
polyethylene, polyethylene naphthalate (PEN), polypropylene (PP), polyphenylene sulphide (PPS), polyether ether ketone (PEEK) and other polymers such as would be appropriate for use in forming monofilament intended for use in papermachine clothing, or as a component or the entirety of a bi-component laser weld enabled film such as is described in CA 2758622. While the '259 document indicates the hydrolytically stabilized film would be suitable for use in the manufacture of such fabrics, it does not provide details as to how it would be produced or what specific characteristics it should include.
The present invention is directed at films suitable for industrial textiles, and such industrial textiles and components thereof such as are described by Manninen in WO 2011/069259, WO 2010/121360, WO 2011/069258, and CA 2,749,477 and which are comprised of bi-axially oriented hydrolytically stabilized polymer films which are resistant to heat, humidity and abrasive wear. It is particularly concerned with such textiles which are intended for use in continuous process applications. These include, but are not limited to, papermaking, where they may be employed as dryer fabrics, through- air dryer (TAD) fabrics, transfer fabrics, press felts, forming fabrics and the like; stock preparation processes such as pulp thickening, pulp forming or in chemi-washers;
agrochemicals preparation such as separation of phosphoric acid in the preparation of potash; solar panels; formation of various construction and building materials such as medium density fiberboard (MDF) and shingles; food drying and related dehydration processes; and formation of nonwoven products in continuous dry laid, wet laid and polymer laid processes. It will be appreciated that textiles intended for use in such industrial processes must be rugged, so as to be capable of surviving the various environmental conditions to which they are exposed during their service life, including the following: abrasion caused by their continuous movement over various stationary elements in the machines in which they are used; high heat and prolonged humidity normally encountered in various drying processes which leads to hydrolytic degradation of the constituent polymers that make up at least a portion of the textile components; and chemical degradation caused by prolonged exposure to acids and bases in various processes. Thus, the textile components from which these fabrics are made must be very durable and as resistant as possible to the various environmental conditions to which they are exposed.
DISCUSSION OF THE PRIOR ART
Bi-axially oriented hydrolytically stabilized polyester films are known. For example, US 6,855,758 to Murschall et al. discloses a hydrolysis resistant bi-axially oriented transparent film made from a crystallizable thermoplastic polyester including a hydrolysis stabilizer consisting of a bond restoration agent such as a monomeric or polymeric carbodiimide and optionally at least one of either a phenolic compound or organic phosphate. The film is said to exhibit good optical properties, in that it has a high light transmittance (above 80%), low haze and a low Yellowness Index (YI), i.e. below 10. However, carbodiimide type hydrolysis stabilizers such as Stabaxol® P are milky in appearance and, for this reason, films which include a carbodiimide hydrolysis stabilizer cannot generally have overall thicknesses greater than ΙΟΟμηι without becoming at least partially opaque, which would not provide the required optical properties of the film. The films produced in accordance with the teachings of Murschall et al. must necessarily have a thickness of less than ΙΟΟμιη, so as to be at least partially transparent. Films of this thickness or less would be unsuitable for use in industrial textiles intended for use in industrial processes such as papermaking and filtration such as are described above, and are not contemplated in the reference. US 6,020,056 to Walker et al. discloses a bi-axially oriented hydrolytically stabilized PET film which does not employ end-capping agents such as carbodiimides. The PET has an initial IV of from 0.95 to 1.1 and, when cast, has an IV of from about 0.8 to 1.0; the resulting film is stretched and oriented at least two times in the machine and cross- machine directions to provide a final monolayer film having an intended end use as a motor insulation.
US 7,229,697 to Kliesch et al. discloses a hydrolysis stabilized PET film whose thickness is from 0.4 to 500 μηι , using alternatives to carbodiimides as hydrolysis stabilizers for PET to address health issues relating to the off-gassing of isocyanates during extrusion and increases in the molecular weight of the PET and extrusion problems associated with it.
WO 2011/030098 to Brennan et al. discloses a bi-axially oriented PET film further including a hydrolysis stabilizer which is a glycidyl ester of a branched monocarboxylic acid having from 5 to 50 carbon atoms and which is present in the film as its reaction product along with some of the polyester end-groups. The proposed benefit of this stabilizer is the alleged lack of toxic by-products and economy of manufacture. Use of the film as a layer in a photovoltaic cell is disclosed.
It is known from US 5,885,709 to Wick et al. to provide uni-axially oriented hydrolysis resistant polyester fibers and filaments which have capped carboxyl end groups following reaction with carbodiimides. The polyesters can include any aliphatic or aromatic filament forming polyester (e.g. PET) with preference given to those having a molecular weight corresponding to an intrinsic viscosity (IV) of at least 0.64 and preferably at least 0.7 dL/g as measured in dichloroacetic acid at 25°C.
US 6,649,247 and US 6,841,222 both to Murschall et al. disclose coextruded bi-axially oriented polyester films including a flame retardant in which the total film thickness ranges from 3 to 350 μηι and the intermediate layer thickness ranges from about 5% to 90% of the total thickness.
It has now been found that it is possible to provide a film for use in an industrial textile, or textiles and components thereof, comprising a bi-axially oriented, multi-layer hydrolytically stabilized polymeric film. The film is not required to be transparent, and for some applications opacity may be advantageous, for example for purposes of monitoring the condition of the film, or a product being conveyed by the film. The film may include, for example, a suitably profiled and apertured film, or an industrial textile constructed of the film, or a component of such textile, such as a nonwoven seaming element, such as are described in the aforementioned patent applications in the name of the present inventor. In order to be useful and have physical properties sufficient to allow such textiles and their components to survive the various rigors of the environment for which they are intended, a suitable film should be formed from a medium to high IV polyester; the IV should be between about 0.55 and 1.0. At least one layer of the film must also be hydrolytically stabilized to prevent premature depolymerization in hot and moist environments due to hydrolytic degradation; carbodiimides are preferred for this application. The film must be stretched and oriented as it is produced so as to increase and maximize its elastic modulus and other physical properties, in particular its tensile strength, which should be at least about 140 Mpa in the machine direction (MD) and 165 MPa in the transverse direction (TD) (also known as cross-machine direction, (CD)) in the finished film, and its free shrinkage, which should be in the range of from 0.5% to no more than 2% in each of the MD and TD, and is preferably about 1 % in each. The film is comprised of at least two and preferably three coextruded miscible layers in which at least one outer layer comprises from 5% to 20% of the overall film thickness which may be from about 100 up to 500 μπι, but in most cases preferably in the range of about 250 to 350μηι. This caliper should be uniform throughout. SUMMARY OF THE INVENTION
In a first broad embodiment, the present invention seeks to provide an industrial textile comprising a biaxially oriented multilayer thermoplastic film including at least two coextruded film layers, wherein
(i) each layer comprises a polyester having an intrinsic viscosity (IV) of at least
0.5;
(ii) at least a first layer comprises a hydrolytic stabilizer comprising a carbodiimide; and
(iii) the film has a thickness of at least 1 ΟΟμιτι and
(iv) the first layer of the film comprises at least 5% of the film thickness.
The invention further seeks to provide a biaxially oriented multilayer thermoplastic film, wherein
(i) each layer comprises a polyester having an intrinsic viscosity (IV) of at least 0.5;
(ii) at least one layer comprises a hydrolytic stabilizer comprising a carbodiimide; and
(iii) the film has a thickness of at least ΙΟΟμπι. Preferably, the polyester for each layer of the film or textile is selected from one of PET, PBT, PEN, PCTA, and more preferably the polyester for each layer is PET. Preferably, the IV is in the range of 0.5 to 1.0.
Preferably, the film thickness is in the range of ΙΟΟμπι to 500μιη. Where the film or industrial textile comprises two layers, preferably a first layer comprises from 5% to 15% of the film thickness and the second layer comprises from 85% to 95% of the film thickness; and more preferably the first layer comprises substantially 10% of the film thickness and the second layer comprises substantially 90% of the film thickness. Where the film or industrial textile comprises three layers, preferably each outer layer comprises from 5% to 20% of the film thickness and an inner layer comprises from 60% to 90% of the film thickness; and more preferably each outer layer comprises from 10% to 15%) of the film thickness and the inner layer comprises from 70% to 80% of the film thickness.
Preferably, for each layer comprising a hydrolytic stabilizer, the carbodiimide comprises between 0.5%pbw and 5%pbw of the material of that layer. Preferably also the carbodiimide is selected from a monomelic form and a polymeric form, more preferably the carbodiimide is polymeric.
Preferably, the film is stretched in each of a longitudinal and a transverse direction by a factor of from two to at least four, more preferably by a factor of at least three. The resulting film is subsequently annealed, cooled and formed into rolls for later use.
Optionally, at least one layer further comprises an additive, such as at least one of carbon black, titanium dioxide, and at least one dye.
Optionally, at least one layer further comprises an antiblock agent.
Alternatively, at least one layer further comprises a radiant energy absorbent material.
The invention further seeks to provide an industrial textile comprising a biaxially oriented multilayer thermoplastic film according to the films of the invention.
The invention still further seeks to provide a component for use with an industrial textile, comprising a film strip prepared from a film according to the invention. The invention still further seeks to provide a component for use in an industrial textile, the component comprising a biaxially oriented multilayer thermoplastic film including at least two coextruded film layers, wherein
(i) each layer comprises a polyester having an intrinsic viscosity (IV) of at least 0.5;
(ii) at least a first layer comprises a hydrolytic stabilizer comprising a carbodiimide; and
(iii) the film has a thickness of at least ΙΟΟμηι and
(iv) the first layer of the film comprises at least 5% of the film thickness.
Preferably, the component is constructed of a multilayer thermoplastic film according to the invention.
In one embodiment, the component comprises a seaming element constructed and arranged to be secured to a seamable edge of the industrial textile.
Preferably, at least where the film is to be used in a continuous moving process, the film has a tensile strength of at least about 140 MPa in each of the MD and the TD. More preferably, the MD tensile strength is at least about 140 MPa and the TD tensile strength is at least about 165 MPa. Tensile strength is measured according to the method provided in ASTM D882 entitled "Standard Test Method for Tensile Properties of Thin Plastic Sheeting" and is a measure of the ultimate or maximum stress of a film at failure.
Preferably, the film has an elongation at break that is at least about 160% in each of the MD and TD as determined according to the method provided in ASTM D882. Elongation at break is the percentage increase in length of the film at failure.
Preferably, the film exhibits a low free shrinkage that is in the range of from about 0.25% to no more than 2% when measured at 150°C for 10 minutes as determined by ASTM D1204 "'Standard Test Method for Linear Dimensional Changes of Nonrigid
Thermoplastic Sheeting or Film at Elevated Temperature". More preferably, the free shrinkage is no more than about 1 % when measured according to that method. Free shrinkage is the percentage reduction in a length of film material under zero tension when subjected to a specified temperature. Preferably, the hydrolysis stabilizer is a carbodiimide and is added to and blended with the polyester in masterbatch form sufficient to comprise from about 0.1% to 5% pbw (parts by weight), preferably about 0.5% to 3% pbw and more preferably about 1.5% to 3% pbw based on the weight of the material in each film layer. Preference is presently given to aromatic polymeric carbodiimides; alternatively the carbodiimide is monomeric.
Preferably, the carbodiimide is incorporated as a masterbatch in the polymer melt.
When intended for use to form nonwoven industrial textiles or components thereof, the film can be processed in one of several ways. For example, for a slit and profiled textile, it may be cut first to a desired size and then a desired topography imparted by means of a thermoforming process whereby heat and pressure are used to deform the film out of plane into a desired shape. The film can then be slit by either mechanical means or by means of radiant energy such as from tuned laser. Alternatively, the film can first be slit or perforated by chosen means, and then embossed with a suitable pattern. In either case, the slit and profiled film sections are then assembled into nonwoven industrial textiles and associated components using known means. As a further alternative, the film may first be embossed according to a desired pattern, and then assembled in two or more layers, and finally perforated as desired.
DETAILED DESCRIPTION OF THE INVENTION
The films, industrial textiles and components of the invention are formed from an extruded and bi-axially oriented film which is comprised of at least one, and preferably three coextruded polymeric layers that are oriented and heatset together, and which include a hydrolysis stabilizer in the form of a monomeric or polymeric carbodiimide. Depending on the intended end use of the film, it will generally be necessary to increase its resistance to hydrolysis. Hydrolysis is a chemical process by which a water molecule is added to a substance resulting in that substance splitting into two parts. It is the type of reaction that will break down certain polymers, especially those such as PET which are made by condensation polymerization. Hydrolysis stabilizers are often added to PET resins when the intended end product will be used in hot and moist environments.
Hydrolysis stabilization additives are well known and function by reacting with free polymeric carboxyl end groups in the polymer melt prior to extrusion. One such additive, which has proven successful when incorporated into polyester monofilaments, is
Stabaxol® KE7646. This additive is commercially available from Rhein Chemie Corp. of Chardon, OH and is comprised of from about 10% to 30% pbw of a polymeric carbodiimide in 70 to 90% pbw of a high IV PET (IV approx. 0.80). A monomelic form of the Stabaxol® additive is also available and is anticipated to be equally as successful in imparting hydrolysis resistance as the polymeric form; either form is suitable for use in the polymeric films and industrial textiles and components of the invention.
As examples only of polyesters suitable for use in the films of the invention, it has been found that Invista Type 4027 PET (available from Invista S.a.r.l. of Wichita, Kansas) having an IV of about 0.60, Invista Type 8326 PET at an IV = 0.55, and DAK Americas LLC of Charlotte, NC Type 80 PET which has an IV of 0.80 have proved suitable. These polyesters are commercially available in dry pelletized form from the supplier with the specified IV. If necessary or desired, the IV of these or any other PET resins can be increased by means of known solid state polymerization processes whereby the polyester is exposed to high temperatures and vacuum (or inert gas, to prevent oxidative degradation); the result is a relatively higher molecular weight polyester in comparison to that of the starting material. In general, higher IV PET resins will allow for the production of a film with improved physical properties, in particular resistance to abrasion and hydrolysis, when compared to films produced from resins of lower IV. High intrinsic viscosity polymer resins will allow the resulting films to better withstand the rigorous demands of certain of the industrial environments to which it may be exposed, such as in the hot and moist dryer section of a papermaking machine, or continuous exposure to sunlight on a solar panel.
The Stabaxol® KE7646 is the masterbatch form of a polycarbodiimide; according to the manufacturer, it contains 15% Stabaxol® PI 00 (the active ingredient) uniformly blended in the PET. Addition of 10-20 pbw Stabaxol® KE7646 per 100 pbw PET should provide an active ingredient content of Stabaxol® P100 of 1.5% to 3%, which is the preferred range of carbodiimide hydrolysis stabilizer in the films and components of the present invention. It has been found that compositions including relatively high IV PET (e.g. 0.8, such as is found in the DAK Type 80 resin) and about 5% pbw carbodiimide, or more, may become difficult to reliably extrude; thickness variation, shrinkage and film orientation are problematic because the stabilizer appears to increase crosslinking and extensional viscosity of melt. The films of the invention are made as follows. A desired PET or other polyester resin is first obtained and an appropriate amount of hydrolysis stabilizer is added according to normal blending processes as are known in the art. As previously mentioned, if the end use of the film is as a belt component in a hot and/or humid environment, the polymer should be hydrolysis stabilized and the IV selected as appropriate. The polymer is preferably obtained as resin pellets which are then loaded into the hoppers of the film extruder(s). Once heated to the melt point, the polymer melt is then extruded through a slot die according to techniques and equipment common in the industry. The amorphous prefilm is subsequently quenched on a chill roll and then reheated and oriented in both the MD (machine direction) and TD (transverse direction) so as to impart stretch-induced structure through biaxial orientation. This step is important in order to provide a mechanically stable film as the stretching process will straighten out the polymer chains in the film and provide crystals with the desired morphology. Stretching temperatures are normally above the glass transition temperature Tg by at least 10°C. The stretching ratio in each of the MD and TD will be about 3, but may range from 2 to about 4 as required. There are essentially two film stretching processes in use at present: simultaneous stretching, in which the film is exposed to both MD and TD force simultaneously; and sequential stretching, in which the film is exposed first to MD and then TD stretch forces. The films of the invention can be made using the simultaneous stretch process, or sequential stretching. Depending on the end use of the film, it may be desired to preferentially stretch the film in one of these directions over the other. A second subsequent stretch in either or both the MD and TD may be employed as needed. The MD and TD shrinkage can be adjusted as appropriate by temperature settings and frame geometry. It should be noted that, as film thickness and carbodiimide content increases, it becomes increasingly difficult to reliably and uniformly control properties, particularly thickness. Heat setting or annealing of the film at oven temperatures of about 180°C to 260°C follows stretch and orientation; the film is then cooled and wound. The oriented film preferably has a final thickness of from about 175 μηι to 350μπι; depending on the intended end use, the film thickness may be increased or decreased around these limits as necessary.
Films made according to the process described above should ideally have a tensile strength of at least about 140 MPa in both the MD and the TD so as to be useful in the manufacture of industrial textiles and components thereof. Preferably, the TD tensile strength of the film will be higher than the MD tensile strength and will be at least about 165 MPa. As previously noted, tensile strength is determined according to the method described in ASTM D882. In addition, films made according to the procedure should provide an elongation at break that is at least about 160% in each of the MD and TD, also as determined according to the method provided in ASTM D882. The films of the present invention exhibit a low free shrinkage, i.e. in the range of from about 0.25% to no more than 2% when measured according to the test method described in ASTM D1204. It is preferred that the free shrinkage of the film be no more than about 1% when measured according to the aforementioned method. The polyester films of the invention may be monolayer films, but are preferably multilayer and more preferably are comprised of three layers. In experimental trials, the film was extruded using a three layer die with a feedblock designed to feed both outside skins from one extruder and the core layer from another. The resultant film thus included three polymer layers arranged according to an A-B-A configuration in which each of A and B are essentially the same polymer but are of two differing thicknesses. It was found that multilayer films of the invention in which the layers A each accounted for 15% of the overall film thickness and the layer B provided the remaining 70% were particularly suitable for use as components in industrial textiles, however, other film thickness ratios such as 10-80-10 may also prove suitable. Preference is given to A-B-A or A-B-C three layer structures. In such structures, it is possible for at least one and preferably both of the outer layers and an intermediate layer to include the hydrolysis stabilizer. The
concentration of the stabilizer may vary from one layer to the next. However, in such structures, it is important that the adjacent layers be compatible, or miscible; alternatively a so-called "tie layer" may be located in between the adjacent layers to prevent layer separation and provide a unified film structure.
The hydrolytically stabilized film of the present invention bears some similarities to the coextruded laser weld enabled film described in CA 2,758,622 (Manninen). As described in that document, one layer of the film is different from the others in that it includes a laser weld enabling material. In the present invention, the film is comprised entirely of essentially the same polymer (although a dye or other common additive may be included in one or more of the layers). For example, it may be necessary to provide an antiblock agent, such as Invista V388 (available from Invista S.a.r.l. of Wichita, Kansas) at a 5% pbw concentration, to the outer "A" layers of the film to prevent them from sticking to a roll or other component of the extruder and/or stretching arrangement.
The polymer films of the present invention are of particular importance to the industrial textile industry for several reasons. First, they are formed from a higher IV PET resin than others that have been used previously and which are commercially available PET films. It has been found that the high IV PET retards brittle crystal formation during heatsetting/thermoforming steps. Commercially available PET films are formed from polyester resins whose IV is less than 0.5; if exposed to heat in the range of about 200°C or more, or prolonged exposure to sunlight, such films will become very brittle and fail in various ways (their tensile strength will diminish, they will become prone to stress cracking, etc.) whereas the films of the present invention will not degrade in this manner. Also, the grade of the PET resin is important when the end use application involves hydrolysis; generally the resin should have a relatively low carboxyl end group concentration and contain low residual diethylene glycol. Further, the hydrolysis stabilizer is reactive and affects the extensional viscosity of melt of the blend - therefore the stabilizer loading affects the processability of the film. It has been found that the quality of the film is significantly affected by the line process parameters, i.e.
temperatures, stretching ratio, etc. The films and textile components of the present invention are highly resistant to hydrolytic degradation. When placed in saturated steam at 125°C and 19 PSIG (pounds per square inch gauge) (131 kPa), or 33.7 PSI (232 kPa) absolute pressure, for an extended period, samples of film made in accordance with the teachings of the invention retained at least 75% tensile strength after six days.
The finished films of the invention can thus be used for the various purposes noted above, where resistance to degradation and embrittlement are important, particularly for the manufacture of industrial textiles which are uniquely suitable for conveyance, filtration and separation processes. For example, hydrolytically stabilized PET film having a thickness of from about 250μηι to about 350μπι is suitable for use in the production of selectively slit and embossed films intended for subsequent assembly as nonwoven papermaking fabrics. Similar films of greater or lesser thickness will be appropriate for the manufacture of seaming components which will be used to join the opposing ends of these fabrics on the machines for which they are intended.

Claims

I CLAIM:
1. An industrial textile comprising a biaxially oriented multilayer thermoplastic film including at least two coextruded film layers, wherein
(i) each layer comprises a polyester having an intrinsic viscosity (IV) of at least
0.5;
(ii) at least a first layer comprises a hydrolytic stabilizer comprising a carbodiimide; and
(iii) the film has a thickness of at least ΙΟΟμπι and
(iv) the first layer of the film comprises at least 5% of the film thickness.
2. An industrial textile according to Claim 1, wherein the polyester for each layer is selected from one of PET, PBT, PEN, PCTA.
3. An industrial textile according to Claim 2, wherein the polyester for each layer is PET.
4. An industrial textile according to any one of Claims 1 to 3, wherein the IV is in the range of 0.5 to 1.0.
5. An industrial textile according to any one of Claims 1 to 4, wherein the film thickness is in the range of ΙΟΟμηι to 500μπι.
6. An industrial textile according to any one of Claims 1 to 5 comprising two layers, wherein a first layer comprises from 5% to 15% of the film thickness and the second layer comprises from 85% to 95% of the film thickness.
7. An industrial textile according to Claim 6, wherein the first layer comprises substantially 10% of the film thickness and the second layer comprises substantially 90% of the film thickness.
8. An industrial textile according to any one of Claims 1 to 5, comprising three layers, wherein each outer layer comprises from 5% to 20% of the film thickness and an inner layer comprises from 60% to 90% of the film thickness.
9. An industrial textile according to Claim 8, wherein each outer layer comprises from 10% to 15% of the film thickness and the inner layer comprises from 70% to 80% of the film thickness.
10. An industrial textile according to any one of Claims 1 to 9 wherein for each layer comprising a hydrolytic stabilizer, the carbodiimide comprises between 0.5%pbw and
5%pbw of the material of that layer.
1 1. An industrial textile according to any one of Claims 1 to 10, wherein the carbodiimide is selected from a monomeric form and a polymeric form.
12. An industrial textile according to Claim 1 1, wherein the carbodiimide is polymeric.
13. An industrial textile according to any one of Claims 1 to 12, wherein the film is stretched in each of a longitudinal and a transverse direction by a factor of from two to at least four.
14. An industrial textile according to Claim 13, wherein the film is stretched by a factor of at least three.
15. An industrial textile according to any one of Claims 1 to 14, wherein at least one layer further comprises an additive.
16. An industrial textile according to Claim 15, wherein the additive is selected from carbon black, titanium dioxide, and at least one dye.
17. An industrial textile according to any one of Claims 1 to 15, wherein at least one layer further comprises an antiblock agent.
18. An industrial textile according to any one of Claims 1 to 15, wherein at least one layer further comprises a radiant energy absorbent material.
19. An industrial textile according to any one of Claims 1 to 18, wherein the film has a tensile strength at least 140MPa.
20. An industrial textile according to any one of Claims 1 to 19, wherein the film has an elongation at break of at least 160%.
21. A biaxially oriented multilayer thermoplastic film, wherein
(i) each layer comprises a polyester having an intrinsic viscosity (IV) of at least 0.5;
(ii) at least one layer comprises a hydrolytic stabilizer comprising a carbodiimide; and
(iii) the film has a thickness of at least ΙΟΟμιη.
22. A film according to Claim 21, wherein the polyester for each layer is selected from one of PET, PBT, PEN, PCTA.
23. A film according to Claim 22, wherein the polyester for each layer is PET.
24. A film according to any one of Claims 21 to 23, wherein the IV is in the range of 0.5 to 1.0.
25. A film according to any one of Claims 21 to 24, wherein the film thickness is in the range of ΙΟΟμηι to 500μηι.
26. A film according to any one of Claims 21 to 25 comprising two layers, wherein a first layer comprises from 5% to 15% of the film thickness and the second layer comprises from 85%) to 95% of the film thickness.
27. A film according to Claim 26, wherein the first layer comprises substantially 10% of the film thickness and the second layer comprises substantially 90% of the film thickness.
28. A film according to any one of Claims 21 to 25, comprising three layers, wherein each outer layer comprises from 5%> to 20% of the film thickness and an inner layer comprises from 60% to 90%> of the film thickness.
29. A film according to Claim 28, wherein each outer layer comprises from 10%> to 15%) of the film thickness and the inner layer comprises from 70% to 80% of the film thickness.
30. A film according to any one of Claims 21 to 29 wherein for each layer comprising a hydrolytic stabilizer, the carbodiimide comprises between 0.5%>pbw and 5%pbw of the material of that layer.
31. A film according to any one of Claims 21 to 30, wherein the carbodiimide is selected from a monomeric form and a polymeric form.
32. A film according to Claim 31 , wherein the carbodiimide is polymeric.
33. A film according to any one of Claims 21 to 32, wherein the film is stretched in each of a longitudinal and a transverse direction by a factor of from two to at least four.
34. A film according to Claim 33, wherein the film is stretched by a factor of at least three.
35. A film according to any one of Claims 21 to 34, wherein at least one layer further comprises an additive.
36. A film according to Claim 35, wherein the additive is selected from carbon black, titanium dioxide, and at least one dye.
37. A film according to any one of Claims 21 to 35, wherein at least one layer further comprises an antiblock agent.
38. A film according to any one of Claims 21 to 35, wherein at least one layer further comprises a radiant energy absorbent material.
39. A film according to any one of Claims 21 to 38, having a tensile strength of at least 140MPa.
40. A film according to any one of Claims 21 to 39, having an elongation at break of at least 160%.
41. An industrial textile comprising a biaxially oriented multilayer thermoplastic film according to any one of Claims 21 to 40.
42. A component for use with an industrial textile, comprising a film strip prepared from a film according to any one of Claims 21 to 40.
43. A component for use in an industrial textile, the component comprising a biaxially oriented multilayer thermoplastic film including at least two coextruded film layers, wherein
(i) each layer comprises a polyester having an intrinsic viscosity (IV) of at least 0.5; (ii) at least a first layer comprises a hydrolytic stabilizer comprising a carbodiimide; and
(iii) the film has a thickness of at least ΙΟΟμηι and
(iv) the first layer of the film comprises at least 5% of the film thickness.
44. A component according to Claim 43, wherein the multilayer thermoplastic film comprises a film according to any one of Claims 21 to 40.
45. A component according to Claim 43, comprising a seaming element constructed and arranged to be secured to a seamable edge of the industrial textile.
PCT/CA2013/000515 2012-05-28 2013-05-28 Industrial textiles comprised of bi-axially oriented, hydrolytically stabilized polymer film WO2013177670A1 (en)

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PCT/CA2013/000515 WO2013177670A1 (en) 2012-05-28 2013-05-28 Industrial textiles comprised of bi-axially oriented, hydrolytically stabilized polymer film

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CN103724608A (en) * 2013-12-26 2014-04-16 东莞市广海大橡塑科技有限公司 Polyester resin film premix
WO2015024107A1 (en) 2013-08-20 2015-02-26 Astenjohnson, Inc. Double pin seaming element
US9873980B2 (en) 2014-09-25 2018-01-23 Albany International Corp. Multilayer belt for creping and structuring in a tissue making process
US9957665B2 (en) 2014-09-25 2018-05-01 Albany International Corp. Multilayer belt for creping and structuring in a tissue making process

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Cited By (6)

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Publication number Priority date Publication date Assignee Title
WO2015024107A1 (en) 2013-08-20 2015-02-26 Astenjohnson, Inc. Double pin seaming element
CN103724608A (en) * 2013-12-26 2014-04-16 东莞市广海大橡塑科技有限公司 Polyester resin film premix
US9873980B2 (en) 2014-09-25 2018-01-23 Albany International Corp. Multilayer belt for creping and structuring in a tissue making process
US9957665B2 (en) 2014-09-25 2018-05-01 Albany International Corp. Multilayer belt for creping and structuring in a tissue making process
US10415186B2 (en) 2014-09-25 2019-09-17 Albany International Corp. Multilayer belt for creping and structuring in a tissue making process
US10961660B2 (en) 2014-09-25 2021-03-30 Albany International Corp. Multilayer belt for creping and structuring in a tissue making process

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